MULTIPORPUSE PRESS CONTROL AND FORCE VS DISPLACEMENT MONITORING SYSTEM

Transcription

1 AULOMA APM-SI Meca Motion MULTIPORPUSE PRESS CONTROL AND FORCE VS DISPLACEMENT MONITORING SYSTEM

2 PRESS CONTROL AND FORCE VS DISPLACEMENT MONITORING SYSTEM BENEFITS Lonely environment to control servo press job and process monitoring installed in servo drive memory Modular press programs with infinite steps for press to force, press to position and press to relative position Real time process monitoring Servo press diagnosis Enhances defects detection Reduce the scrap cost Operator friendly interface for press program Ethernet interface for data exchange Analysis data in CSV format for SPC PC tool kit compatible with wichever MS Windows 7 machine and later version FEATURES Software Best industrial software for press program and process monitoring Two channels (x)(y) analisys for real time Process Monitoring Multiple waveform control zones Envelope function for complete waveform control Eight additional force limits Waveform trajectory recognition CSV data transfert Hardware Servo Drive with Built-In PLC Siemens Profinet or Ethernet interface for easy plug and wiring Ethernet interface for PC connection No.9 digital input No.5 digital output Capability of memory for 254 press recipes and 254 envelopes force control Quick Set Up Friendly help for set up the servo press parameters Friendly help for set up the wavform control zone 2 PC User Interface Simple and intuitive user display Supervisor account with password security Multiple Data Views Status: see part test status (pass or fail) Curves: view data curves (Force vs. Distance) with overlaid limits History: review last test cycles and part history records Limits: view current limits Detailed Data Management and Reporting Local PC & remote storage of test results organized by model, part, ram, etc. Process data available in CSV format for Statistical Process Control (SPC) Servo Drive Connectivity Communication with station controller via Profinet or Ethernet slave configuration Communication with station controller via discrete I/O in APM slave configuration Ethernet TCP/IP for data transfert USB Applications Servo press control Press applications process monitoring

3 OVERIEW APM-SI is designed to control the servo press motion and in the same time monitoring the press operations,thus the system provide real-time analysis of the data to identify defective parts, faulty press machinery, and out of control assembly processes. It measures force vs. distance signatures for each part cycle, and then analyzes the curve(s) in milliseconds to provide an instant pass/fail output for press ram. Compatible with piezoelectric force sensor or strain gauge amplified with analog output of ±1 0V, APM-SI can be networked to provide higher level insight into assembly processes by collecting data across the entire assembly line. APM-SI-MEMO provides extensive hardware and software functions for part test, analysis and data connectivity APM-SI-MEMO CONFIGURATION STANDARD TO CONTROL PRESS RAM SLAVE MASTER USER PLC PROFINET COMANDS * * ALTERNATIVE BUS AVAILABLE: PROFIBUS ETHERNET MOD/BUS OPTIONAL FOR RELATIVE POSITION SERVO DRIVE CONTROL UNIT IN LIST: RECIPE RESUMERS ENVELOP RESUMERS SWITCH TO MANUAL OR AUTO RAM STROKE IN MANUAL MODE RAM SPEED IN MANUAL MODE RAM ACCELERATION IN MANUAL MODE FORCE SENSOR RANGE START PROGRAM JOG + JOG ABSOLUTE OR RELATIVE RAM POS. START MANUAL RAM POSITION FORCE SENSOR RESET ERRORS AKNOWLEDGE REQUEST TO CHANGE MODE PRESS GO TO HOME POSITION BREAK POINT ENABLE CONTINUE PROGRAM AFTER BREAK LDTV MEASURE PROFINET COMANDS * ENCODER DRIVE CLIQ ANALOG INTERFACE ±1 0v ETHERNET INTERFACE EXTERNAL SENSOR / DIGITAL IN PC LAPTOP WITH APM-PC TOOL INSTALLED OUT LIST: NO. PROGRAM ENABLE NO. ENVELOPE ENABLE MANUAL OR AUTO ENABLE FORCE SENSOR RANGE ACTIVE REAL RAM POSITION RAM SPEED VALUE IN REAL TIME FORCE VALUE IN REAL TIME PROGRAM STEP ACTIVE ABSOLUTE OR RELATIVE RAM POS. END OF MANUAL RAM POSITIONING ALLARM ENABLE RAM IN HOME POSITION PROGRAM IS STOPPED IN A BREAK ETHERNET SWITCH PC HMI OR PC SERVER WITH APM-PC TOOL INSTALLED (OPTIONAL) OTPTICAL MAGNETIC CAPACITIVE SERVO PRESS MOTOR ENCODER PROXIMITY SENSOR FORCE SENSOR 3

4 APM-SI-MEMO CONFIGURATION CLOSE LOOP WITH LINERA ENCODER ON THE RAM SLAVE MASTER USER PLC SERVO DRIVE CONTROL UNIT PROFINET COMANDS * OUT LIST: NO. PROGRAM ENABLE NO. ENVELOPE ENABLE MANUAL OR AUTO ENABLE FORCE SENSOR RANGE ACTIVE REAL RAM POSITION RAM SPEED VALUE IN REAL TIME FORCE VALUE IN REAL TIME PROGRAM STEP ACTIVE ABSOLUTE OR RELATIVE RAM POS. END OF MANUAL RAM POSITIONING ALLARM ENABLE RAM IN HOME POSITION PROGRAM IS STOPPED IN A BREAK OPTIONAL FOR RELATIVE POSITION PROXIMITY SENSOR 4 PROFINET COMANDS * ENCODER DRIVE CLIQ ANALOG INTERFACE ±1 0v ETHERNET INTERFACE EXTERNAL SENSOR / DIGITAL IN PC LAPTOP WITH APM-PC TOOL INSTALLED DRIVE CLIQ HUB ETHERNET SWITCH SMC 40 HEIDENHAIN ENDAT DRIVE CLIQ CONVERTER PC HMI OR PC SERVER WITH APM-PC TOOL INSTALLED (OPTIONAL) SERVO PRESS MOTOR ENCODER LINEAR ENCODER FORCE SENSOR OTPTICAL MAGNETIC CAPACITIVE IN LIST: RECIPE RESUMERS ENVELOP RESUMERS SWITCH TO MANUAL OR AUTO RAM STROKE IN MANUAL MODE RAM SPEED IN MANUAL MODE RAM ACCELERATION IN MANUAL MODE FORCE SENSOR RANGE START PROGRAM JOG + JOG ABSOLUTE OR RELATIVE RAM POS. START MANUAL RAM POSITION FORCE SENSOR RESET ERRORS AKNOWLEDGE REQUEST TO CHANGE MODE PRESS GO TO HOME POSITION BREAK POINT ENABLE CONTINUE PROGRAM AFTER BREAK LDTV MEASURE

5 THREE DIFFERENT KIND OF SERVO PRESS CONTROL APM-SI-MEMO own three mode to control the press ram. The set up of each program is easy and friendly. In few minutes is possible set up the press according your application. The three mode allow a ram control to press at the right force, at the right position or at the right relative position from a force signal trigger or by an external sensor. The press program is saved in the memory of the servo drive unit and within a maximum of 254 recipes THE BEST HUNTER OF PARTS DEFECTS The brain of the APM-SI-MEMO is the powerful CPU that allow a faster analysis of the data gathered from the press sensors. The APM software produce a faster analysis of all data provided by the servo press. The press waveform results are controlled by multiple tolerance off set zones or by an envelope that wrapping the trajectory. Thanks to this method if the process is repeatable the analysis results are repeatable also and by the comparison of a masterpiece waveform the APM can decide in few milliseconds if the parts are correct or wrong. MULTIPLE GRAPHICAL DATA VIEWS The APM displays all informations about press program and test result on a Windows PC machine with APM-SI toll kit installed. Thanks to the icons on the software interface is easy display tables and graphs. The navigation inside the APM-SI Toll kit is protected by password and allow different set up level according the permission. CSV DATA TRANSFERT The APM-SI-MEMO can provide the process signature data in CSV ( Comma Separated Value ) format to an external data storage. The CSV data can be used for SPM ( Statistic Process Management ) or SPC ( Statistic Process Control ) and can be processed by many ERP, MRP and spread sheet ) DEFECTS DETECTED MISSING PART EXCESSIVE DISTANCE PARTS CORRECT ASSEMBLY INSUFFICENT DISTANCE INCORRECT INSERTION INCORRECT ORIENTATION INCORRECT PART APM-SI TOOL KIT FUNCTIONALITY The best yield obtained by Auloma servo press is when all analysis data provided are saved and analysed in a PC machine. Statitistical analysis of your data allow an awared knowledge of your quality trend. Through APM-SI Tool Kit whichever PC machine can set up the press operations but can also save and see all analysis data. With a good organizzation of the archive folders is possible research the data stored through a DB and then analysed by Statistic Process Management installed. 5

6 TOOL KIT PRESS PROGRAM APM-SI displays a templates where is possible choose and edit the variables to control the servo press drive profile. Is possible create complex recipes with multifuncions and manage differents tools and applications. In the same recipes it will be possible execute and monitoring the process for press fit, forming, joining, clincihng, bending, rivetting and more applications. TOOL KIT SETTING LIMITS The APM-SI displays a menu to setting the force limits on wafeform TOOL KIT CURVES VIEW The APM-SI provide each cycle the curves produced by the data gathered. The curve is displayed on (x) (y) graph, where in (x) there is the ram stroke scale and in (y) the force. The view of the curve is aided by a smart zoom function and pan function. The off set force limit settled on the curves can be displayed through the properly buttons on the screen. 6

7 TOOL KIT HISTORY VIEW The APM save each cycle result in two diffrent CSV files. The 1 st file provides the raw data to identify the historical period, the 2nd file provides the raw data about the analysis. Both files are saved on the resperctive folder path. The analysis history is displayed below the curve templates and is possible diplays each historical curves through a flaggable field. THE BEST PROCESS MONITORING FOR PRECISION APPLICATION APM-SI-MEMO is used by: Automotive Watch Industry Electronic Industry Med Tech Weapons Metal forming Appliances Testing 7

8 PRESS PROGRAM For complex press operations or if breakpoints for the supply of material or tools are required, an extended sequence of press fit programs is available. The APM-SI has the capability of infinite steps in sequence to provide operational profiles with breakpoint and inversion of the direction of travel. position set 0 0 position set 1 position set 2 approach home position position set 3 introduction position set 0 end fit home position idle stroke ( fast foward) until workpiece introduction ( slow forwad) for few millimetres to bear the correct workpiece alignment fitting to the target value ( force or position ) position set 0 position set 4 position set 5 position set 0 tool change approach flaring home position 4 5 tool change position idle time for tool changing 8 idle stroke ( fast foward) until workpiece flaring stroke ( slow forward ) to the target value back stroke ( fast bakward) until home position back stroke ( fast backward) until tool change position 0

9 APM-SI PROCESS MONITORING FUNCTIONALITY In contrast to conventional practices of inspecting the finished part for defects, our system can control in run your process and catch defect and abnormalityes. Thnaks to a continue gathering of the servo press sensor feedback the system receives the necessary data to monitor the process and provides the capability to create a warning system. Our APM-SI have the capability of measuring the process variation during production, thus detecting problems at the source before they become quality issues. The analisys is based on a system of comparisons of your processed parts to the waveforms generated by a masterpiece(s) preloaded in the systems. In other words if an acceptable process is known, our system can be calibrated to repeat the known process and produce parts that conform and the process is verifiable consistent and repeatable. A constant control of Force vs Displacement indicates that the resulting part has been produced according to the previously verified acceptable part. By continuously monitoring the measurement parameters of the servo press, it is possible to detect variances that can mean the process is no longer quality capable. Catching defects at the source gives manufacturers the confidence that only good parts are shipped to their customers. FORCE LIMITS SETUP Capability to load several masterpiece curves to determinate the force off set (Hi and Low) limits Capability to set 8 control boxes of Hi and Low force off set values 9

10 Capability to set 8 consecutive control boxes (Envelop) of Hi and Low force off set values to wrapping the waveform Capability to set 8 control zones composed by a mix of Envelop and control boxes Capability to set 8 additional 8 force limits, displayed by horizontal red dashed lines 10

11 WAVEFORM ANALYSIS Capability to recognize the waveform trajectory through the defined intersection with the control boxes. Wrong intersection is displayed in red and provide a warning signal to the master PLC Capability to recognize the waveform trajectory out from the off set Hi and Low force value. Control boxes displayed in red. The system provide a warning signal to the master PLC Capability to recognize the waveform trajectory inside the off set Hi and Low force value. Control boxes displayed in green. The system provide an ok signal to the master PLC 11

12 PRODUCTS OVERVIEW APM-SI - MEMO SERVO DRIVE D WITH POWER UNIT APM-SI SOFTWARE 12

13 PRODUCTS OVERVIEW APM -SI-MEMO CLOSED LOOP SERVO DRIVE D WITH POWER UNIT DRIVE CLIQ HUB HEIDENHAIN SMC 40 EIB 2391 S DRIVE CLIQ INTERFACE APM-SI SOFTWARE 13

14 TECHNICAL SPECIFICATIONS D SERVO DRIVE FEATURES Display and diagnostics LEDs to display operating states and errors 3 measuring sockets Service switch and mode selector Diagnostics button Onboard I/Os 5 digital inputs 8 digital inputs/outputs (max. 8 as output cams or 8 as measuring inputs) 3 fail-safe, two-channel inputs (F-DI); can also be used as 6 DI 1 fail-safe output (F-DO); can also be used as 1 DO 1 analog input (either ± 1 0 V or ± 20 ma) Communication 1 x DRIVE-CLiQ 1 x PROFINET IO (1 interface with 2 ports, D DP/PN only) 1 x PROFIBUS DP (D DP: 2 PROFIBUS DP) Data backup 1 x slot for SIMOTION CompactFlash card Additional interfaces Terminals for 24 V electronics power supply 1 x encoder input for HTL/TTL incremental encoder SSI absolute encoder (without incremental signals) 1 x temperature sensor input (KTY or PTC) PM IF interface (Power Module interface) on rear for direct operation with a SINAMICS S1 20 PM240-2 or PM340 Power Module in blocksize format Auloma Holding S.r.l. Address: Via Mussolina San Pietro in Casale ( BO) ITALY T info@auloma.com Rev APM-SI-MEMO-MMXV Auloma Holding S.r.l., all rights are reserved. It is prohibited to use text or immages from this documentation, in whole or in part, without written permission. All products are subject to technical change without notice. Liability for printing errors in the technical data is excluded. 14